Foot prosthesis with resilient multi-axial ankle

ABSTRACT

The present foot prosthesis includes various structural features that provide the foot with advantageous rollover properties. In certain embodiments, the foot guides rollover toward the medial side. For example, an asymmetrical upper element and a correspondingly shaped resilient ankle member support more of the wearer&#39;s weight on the lateral side as the foot rolls over. In another embodiment, stiffeners added to the resilient ankle member increase the stiffness on the lateral side relative to the medial side. In certain other embodiments, the foot provides progressively increasing support from mid stance through toe off. For example, a gap between the resilient ankle member and the lower element closes during the later portion of the wearer&#39;s gait. The closing gap increases a contact area between the resilient ankle member and the lower element, providing progressively increasing support. In another embodiment, the foot includes a gap between a lower front edge of an attachment adapter and the upper element. The gap may be filled with a resilient material.

RELATED APPLICATIONS

This application is a continuation-in-part of copending application Ser.No. 10/944,436, filed on Sep. 17, 2004, which claims priority toprovisional application Ser. No. 60/575,142, filed on May 28, 2004. Theentire contents of each of these applications are hereby expresslyincorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates in certain embodiments to prosthetic feet.

2. Description of the Related Art

U.S. Pat. Nos. 5,728,177 and 5,800,569 each disclose prosthetic feethaving resilient ankles. Each foot generally comprises a lower footplate, an upper, smaller ankle plate and a layer or block of resilientmaterial that connects the foot plate to the ankle plate. Each foot issized to fit within an outer flexible cosmesis.

U.S. Pat. Nos. 6,206,934 and 6,280,479 each disclose prosthetic feethaving resilient ankle blocks with one or more spring inserts. In eachfoot, the ankle block is sandwiched between a foot element and an ankleelement. The spring inserts increase the rigidity of the foot and alterthe energy storage and return characteristics thereof.

SUMMARY OF THE INVENTION

The preferred embodiments of the present foot prosthesis with resilientmulti-axial ankle have several features, no single one of which issolely responsible for their desirable attributes. Without limiting thescope of this foot prosthesis as expressed by the claims that follow,its more prominent features will now be discussed briefly. Afterconsidering this discussion, and particularly after reading the sectionentitled “Detailed Description of the Preferred Embodiments,” one willunderstand how the features of the preferred embodiments provideadvantages, which include soft heel, stabilization at heel strike,progressive stiffness at heel strike and toe off, smooth rollover,guided rollover, progressively increasing support from mid stancethrough toe off, natural-feeling toe off, variable stiffness duringrollover and a reduction in stresses in members that secure various footcomponents to one another.

One embodiment of the present foot prosthesis comprises a lower element,an upper element, a resilient ankle member and an attachment adapteroperatively connected to an upper surface of the upper element. Theankle member is positioned between the lower and upper elements, andcompletely separates the lower element from the upper element such thatthe lower element does not contact the upper element. A gap existsbetween a lower front edge of the adapter and the upper surface of theupper element.

Another embodiment of the present foot prosthesis comprises, incombination, an elongate, plate-like element adapted for use in aprosthetic foot and an attachment adapter operatively connected to anupper surface of the elongate, plate-like element. A gap exists betweena lower front edge of the adapter and the upper surface. The gapcontains a resilient material.

Another embodiment of the present foot prosthesis comprises, a method ofconstructing a prosthetic foot. The method comprises the steps ofoperatively connecting an attachment adapter to an upper surface of anupper element, such that a gap remains between a lower front edge of theadapter and the upper surface, and filling at least a portion of the gapwith a resilient material.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the present foot prosthesis with resilientmulti-axial ankle, illustrating its features, will now be discussed indetail. These embodiments depict the novel and non-obvious footprosthesis shown in the accompanying drawings, which are forillustrative purposes only. These drawings include the followingfigures, in which like numerals indicate like parts:

FIG. 1 is a front perspective view of a preferred embodiment of thepresent foot prosthesis with resilient multi-axial ankle;

FIG. 2 is a left side elevational view of the foot prosthesis of FIG. 1;

FIG. 3 is a top plan view of the foot prosthesis of FIG. 1;

FIG. 4 is an exploded assembly view of the foot prosthesis of FIG. 1,illustrating the prosthesis from a front perspective view;

FIG. 5 is a front perspective view of the foot element of the footprosthesis of FIG. 1;

FIG. 6 is a left side elevational view of the foot element of FIG. 5;

FIG. 7 is a top plan view of the foot element of FIG. 5;

FIG. 8 is a rear perspective view of the resilient ankle member of thefoot prosthesis of FIG. 1;

FIG. 9 is a right side elevational view of the resilient ankle member ofFIG. 8;

FIG. 10 is a top plan view of the resilient ankle member of FIG. 8;

FIG. 11 is a rear elevational view of the resilient ankle member of FIG.8;

FIG. 12 is a front perspective view of a preferred embodiment of astiffening insert for use with the foot prosthesis of FIG. 1;

FIG. 13 is a front elevational view of the stiffening insert of FIG. 12;

FIG. 14 is a left side elevational view of the stiffening insert of FIG.12;

FIG. 15 is a front perspective view of another preferred embodiment of astiffening insert for use with the foot prosthesis of FIG. 1;

FIG. 16 is a front elevational view of the stiffening insert of FIG. 15;

FIG. 17 is a left side elevational view of the stiffening insert of FIG.15;

FIG. 18 is a front perspective view of the upper element of the footprosthesis of FIG. 1;

FIG. 19 is a left side elevational view of the upper element of FIG. 18;

FIG. 20 is a top plan view of the upper element of FIG. 18;

FIG. 21 is a front perspective view of the pyramid adapter of the footprosthesis of FIG. 1;

FIG. 22 is a left side elevational view of the adapter of FIG. 21;

FIG. 23 is a rear elevational view of the adapter of FIG. 21;

FIG. 24 is a bottom plan view of the adapter of FIG. 21;

FIG. 25 is a left side sectional view of the adapter of FIG. 21 takenalong the line 25-25 in FIG. 23;

FIG. 26 is a right side sectional view of the adapter of FIG. 21 takenalong the line 26-26 in FIG. 23;

FIG. 27 is a bottom perspective view of the foot prosthesis of FIG. 1,further including a functional sole;

FIG. 28 is a front perspective view of an alternative foot element;

FIG. 29 is a front perspective view of another alternative foot element;

FIG. 30 is a front perspective view of another alternative foot element;

FIG. 31 is a front perspective view of another alternative foot element;

FIG. 32 is a front perspective view of another alternative foot element;

FIG. 33 is a front perspective view of another alternative foot element;

FIG. 34 is a front perspective view of another alternative foot element;

FIG. 35 is a front perspective view of another alternative foot element;

FIG. 36 is a front perspective view of another alternative foot element;

FIG. 37 is a front perspective view of another alternative foot element;

FIG. 38 is a left side elevational view of the foot prosthesis of FIG.1, illustrating the deformation of the foot at heel strike;

FIG. 39 is a left side elevational view of the foot prosthesis of FIG.1, illustrating the deformation of the foot at mid stance;

FIG. 40 is a left side elevational view of the foot prosthesis of FIG.1, illustrating the deformation of the foot at toe off;

FIG. 41 is a top view of a scan that maps the movement of the center ofpressure of the foot prosthesis of FIG. 1 as the prosthesis rolls overfrom heel strike to toe off;

FIG. 42 is a front perspective view of another preferred embodiment ofthe present foot prosthesis with resilient multi-axial ankle;

FIG. 43 is a front perspective view of the upper ankle element, adapterand resilient wedge of the foot prosthesis of FIG. 42;

FIG. 44 is an upper plan view of the components of FIG. 43;

FIG. 45 is a right side sectional view of the components of FIG. 43,taken along the line 45-45 in FIG. 44; and

FIG. 46 is a detail view of the resilient wedge portion of FIG. 45,taken along the line 46.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1-4 illustrate one embodiment of the present foot prosthesis withresilient ankle. The prosthesis 50 comprises a resilient ankle member 52sandwiched between a lower element 54, or foot element 54, and an upperelement 56 or ankle element 56. In the illustrated embodiment, the footelement 54 and ankle element 56 are substantially plate-like. Those ofskill in the art will appreciate, however, that the foot element 54 andankle element 56 need not resemble plates.

The resilient ankle member 52 sandwiched between relatively stifferelements 54, 56 enables the foot 50 to flex in multiple planes. The foot50 is thus able to closely mimic the multiaxial movement capabilities ofa natural human foot. Additional applications describe the features andadvantages of a resilient ankle member sandwiched between relativelystiffer elements. For example, pending U.S. Patent Publication No.2003-0093158 A1 discloses a foot prosthesis with a cushioned ankle.Additionally, U.S. Pat. No. 5,800,569 discloses a prosthesis withresilient ankle block.

In one embodiment, the ankle member 52 is constructed of a compressible,resilient and durable material. For example, the ankle member 52 may beconstructed of polyurethane. Alternatively, the ankle member may beconstructed of foam. The ankle member 52 may be constructed withdifferent shore densities in order to accommodate wearers of differentweights. For example, shore densities from 60A to 90A could be provided.

In one embodiment, the elements 54, 56 are constructed of a resilientmaterial that is capable of flexing in multiple directions. The materialmay comprise multiple layers, or laminae. Examples of possible materialsfor the elements 54, 56 are carbon, any polymer material, and anycomposite of polymer and fiber. The polymer could be thermoset orthermoplastic. In a composite, the fiber reinforcement could be any typeof fiber, such as carbon, glass or aramid. The fibers could be long andunidirectional, or they could be chopped and randomly oriented.

If the elements 54, 56 comprise multiple layers, or laminae, the layersmay be arranged as follows. An upper layer and a lower layer may eachcomprise cloth having fibers oriented at −45° and 45° to a longitudinalaxis of the element 54, 56. A next uppermost layer and a next lowermostlayer may each comprise a sheet of fibrous material, such as carbon. Thefibers may be unidirectional and oriented at 90° to the longitudinalaxis. Additional layers in between may each comprise a sheet of fibrousmaterial, such as carbon. The fibers may be unidirectional and orientedwithin the range of plus or minus 45° to the longitudinal axis. Theremay be any number of these intermediate layers.

The construction described above provides the elements 54, 56 withmultidirectional strength. Additionally, orienting all intermediatelayers within the range of plus or minus 45° to the longitudinal axismaximizes fiber surface alignment, which increases the bonding strengthbetween the layers.

In an alternate construction, each of the elements 54, 56 is laid upsubstantially as described above. However, in the lower element 54, anuppermost layer thereof is oriented within the range of plus or minus45° to the longitudinal axis, and the element 54 includes no cloth layeron top. Rather, when the element 54 is laid up, a rough weave fabric isplaced over the uppermost layer. Prior to curing, this fabric layer isremoved. The rough weave leaves behind a roughened surface on theuppermost layer of the element 54. The element 54 is then cured tosolidify the roughened upper surface. The lowermost layer of the lowerelement 54 may be oriented within the range of plus or minus 45° to thelongitudinal axis.

In this same construction, the upper element 56 is similarly laid upsuch that a lowermost layer thereof is oriented within the range of plusor minus 45° to the longitudinal axis, and the element 54 includes nocloth layer on the bottom. The surface of the lowermost layer thereof isroughened in the same manner described above. The roughened surfaces ofthe elements 54, 56 are adapted to be secured to the respective abuttingsurfaces of the ankle member 52, as described below. In thisconstruction, the resilient ankle member 52 enhances themultidirectional strength of the elements 54, 56 as it flows over stressareas therein.

This layered construction is illustrated below:

Cloth with fibers at −45° and 45°;

Unidirectional layer at 90°;

A plurality of unidirectional layers within the range of plus or minus45°;

A lowermost unidirectional layer within the range of plus or minus 45°;

A roughened lower surface;

Ankle member 52;

A roughened upper surface;

An uppermost unidirectional layer within the range of plus or minus 45°;

A plurality of unidirectional layers within the range of plus or minus45°; and

Cloth with fibers at −45° and 45°.

All layers listed above the ankle member 52 comprise the upper element56. All layers listed below the ankle member 52 comprise the lowerelement 54.

In use, the foot 50 may be covered by a cosmesis (not shown) to make theoverall assembly appear as natural as possible. For example, Applicant'scopending application filed on the same day herewith discloses afunctional foot cover that is well adapted for use with the present foot50. This copending application, titled “Functional Foot Cover”, isattached hereto as an appendix and is to be considered a part of thisspecification, and is expressly incorporated by reference herein in itsentirety. Those of skill in the art will appreciate that the foot 50 isfully functional on its own, and may be used without a cosmesis.

With reference to FIGS. 5-7, the foot element 54 includes a toe portion58, a heel portion 60 and an arch portion 62. The foot element 54 may besized and shaped similarly to the natural human foot for which itsubstitutes. Thus, with reference to FIG. 7, the heel portion 60includes a substantially constant width. The arch portion 62 includes asubstantially constant width in a region that is proximate the heelportion 60, and then gradually widens as it approaches the toe portion58. The toe portion 58 includes a width that increases in a directionaway from the arch portion 62, and then tapers inwardly to an anterioredge 64.

The outwardly bulging lateral edge 66 in the toe portion 58 contributesto a more natural toe off. In the human foot, the center of mass travelsapproximately through the big toe and the second toe as the foot rollsover from heel strike to toe off. In the present foot prosthesis 50, theoutwardly curved lateral edge 66 helps to guide the travel of the foot'scenter of mass toward the medial side 68, so that it travels through thearea where the big toe and second toe would be located if a human footwere superimposed over the foot element 54. This path for the center ofmass creates a more natural-feeling toe off, which in turn contributesto an overall more natural feel for the wearer of the present prosthesis50. As described more fully below, the outwardly curved lateral edge 66does not achieve this advantageous result by itself. Instead, thelateral edge 66 achieves this advantageous result in combination withother features of the foot 50.

The toe portion 58 includes a generally U-shaped cut-out portion 70 atthe anterior end 64 thereof. The cut-out 70 is positioned toward amedial side of a longitudinal axis of the foot element 54, but is spacedfrom the medial edge 68 of the foot element 54. The cut-out 70 gives thefoot element 54 a “sandal toe” appearance. This sandal toe is adapted toengage mating structure within a cosmesis. The cosmesis provides thefoot 50 with a more anatomical look.

The sandal toe also enables the foot element 54 to maintain a moreanatomical look while providing a full length toe lever. The full lengthtoe lever provides greater energy return at toe off and contributes to afull length stride. Further, the cut-out 70 provides the toe portion 58with a lesser stiffness on the medial side thereof. The lesser stiffnesson the medial side enhances the travel of the foot's center of masstoward the medial side as the foot 50 rolls over.

In an alternate configuration (not shown), the cut-out 70 may bepositioned toward a lateral side of a longitudinal axis of the footelement 54. In this configuration, the cut-out 70 provides the toeportion 58 with a lesser stiffness on the lateral side thereof. Thelesser stiffness on the lateral side enhances the travel of the foot'scenter of mass toward the lateral side as the foot 50 rolls over.

The heel portion 60 includes a longitudinal split 72 that extendssubstantially along the longitudinal axis of the foot element 54. Thesplit 72 extends into a region of the arch portion 62 that is proximatethe heel portion 60. The split 72 provides a narrow gap between a medialportion 74 and a lateral portion 76 of the heel portion 60. The split 72terminates in a rounded fillet 78 that helps prevent the formation ofstress concentrations in that region. Such stress concentrations couldpropagate a crack through the foot element 54.

The split 72 in the heel portion 60 helps the heel portion 60 to conformto uneven ground, which helps to stabilize the foot 50 during heelstrike. For example, the medial portion 74 may strike a pebble, whilethe lateral portion 76 strikes flat ground. In such a situation, theseparate medial and lateral portions 74, 76 move independently of oneanother to conform to the uneven ground. The medial portion 74 deflectsa greater amount than the lateral portion 76 does. The pebble thus doesnot place as great a torque on the foot element 54 as it otherwise wouldin the absence of the heel split 72. Such torque would tend to twist theentire foot 50, leading to overall instability. The heel split 72 helpsto avoid such instability.

In one embodiment, illustrated in FIG. 27, a lower surface of the footelement 54 includes a functional sole 234. The sole 234 providesadvantageous rollover properties, as described below. The sole 234 issecured, for example by bonding, to the lower surface of the footelement 54. The functional sole 234 comprises portions of resilient andcompressible material. Example materials include EVA and polyurethane.In the illustrated embodiment, a first portion 236 of resilient andcompressible material covers most of the foot element lower surface. Inan alternate embodiment, the first portion 236 may cover the entirety ofthe foot element lower surface. The first portion 236 includes aperimeter that is shaped substantially the same as the foot elementperimeter.

The first portion 236 includes internal irregularly shaped holes. Afirst hole 238 is substantially round and is located at the heel portion60. The first hole 238 may be asymmetrically shaped, having first andsecond projections, one on the medial side of the foot and the other onthe lateral side of the foot. The medial projection may extend fartheranteriorly than the lateral projection.

A second hole 240 is oblong with a substantially V-shaped indentation242 and is located approximately where the ball of the foot would be ifa human foot were superimposed over the foot element 54. The second holeis preferably provided on the medial side of the foot, with the bottomof the V preferably pointing toward the big toe of the foot.

Inserts 244, 246 comprising resilient and compressible material(s)occupy the holes 238, 240. In one embodiment, the inserts 244, 246 havedifferent material properties than the material comprising the firstportion 236. For example, the inserts 244, 246 may be more readilycompressible, or less dense, than the first portion material.

The more compressible insert 244 advantageously provides additionalshock absorption in the heel portion 60 of the foot 50. Moreover, theasymmetry of the insert 244 toward the medial side, and the mediallyplaced insert 246, provide additional compressibility overall to themedial side of the foot 50. This configuration guides the center of massof the foot 50 toward the medial side as the foot rolls over from heelto toe. In each of these embodiments, the inserts 244, 246 arepreferably surrounded by the material of the first portion 236, toprovide desired support to the foot 50 at the edges of the sole 234.

In an alternate configuration, the insert 246 may comprise a materialthat is less compressible than the material of the first portion 236. Inthis configuration, the stiffer medial side of the foot 50 guides thecenter of mass of the foot 50 toward the lateral side as the foot 50rolls over from heel to toe.

In another alternate configuration, the insert 246 may be located alongthe lateral side of the toe portion of the foot element 54. In such aconfiguration, the material composition of the insert 246 affects therollover properties of the foot 50. If the insert 246 is softer than thefirst portion 236, then the foot's center of mass is guided toward thelateral side as the foot 50 rolls over from heel to toe. Conversely, ifthe insert 246 is stiffer than the first portion 236, then the foot'scenter of mass is guided toward the medial side as the foot 50 rollsover from heel to toe.

Those of skill in the art will appreciate that additional holes could beprovided in the first portion 236, and that these additional holes couldbe positioned anywhere in the first portion 236 to give the foot 50desired rollover properties. Any additional holes could also be filledwith inserts. These additional inserts could have material propertiesdifferent that are different from one another, and different from thematerial properties of the first portion 236.

Those of skill in the art will appreciate that although the sole 234 isprovided with inserts 244, 246 of different stiffness orcompressibility, other techniques may be used to vary thecompressibility of the sole 234. For example, small holes orperforations may be provided in desired locations of the sole 234, suchas beneath the heel and/or at the ball of the foot on the medial side.The lack of material at these locations can desirably add to thecompressibility or reduced stiffness of the sole 234. Any suchembodiment that provides a varying stiffness to the sole 234 in desiredlocations is contemplated. In particular, any embodiment that varies thestiffness of the sole 234 at particular locations to help guide adesired rollover of the foot 50 is contemplated.

With reference to FIG. 6, in one embodiment an upper surface 80 of thefoot element 54 includes a concave curvature in the toe portion 58 andthe heel portion 60. A lower surface 82 of the foot element 54 includesa concave curvature in the arch portion 62. The upwardly curved heelportion 60 helps to ensure that the heel portion 60 does not strike theground along the posterior edge 84. Instead, a portion 86 of the heelforward of the posterior edge 84 strikes the ground during heel strike.This portion 86 has a greater surface area than the posterior edge 84.Thus, at heel strike, the foot 50 is more stable because more of it isin contact with the ground.

The upwardly curved toe portion 58 (and the convex curvature on the footelement 54 lower surface at the toe portion 58) provides an easierrollover through the toe portion 58. The curved arch portion 62simulates the natural curvature of the arch in the human foot. The footelement 54 thus provides a more natural rollover through the mid stance.In addition, the arch portion 62 tends to flex through the mid stance,which provides additional shock absorption.

With continued reference to FIG. 6, in one embodiment the foot element54 has a variable thickness along its length. The toe and heel portions58, 60 are relatively thin, while the arch portion 62 is relativelythick. If the material composition of the foot element 54 is uniformover its entire area, then the areas of variable thickness will providethe foot element 54 with areas of variable stiffness. In theconfiguration shown in FIG. 6, for example, the toe and heel portions58, 60 are relatively more flexible than the arch portion 62 is. Thisconfiguration provides an easier rollover, because the foot element 54is more compliant at the toe and heel portions 58, 60. Those of skill inthe art will appreciate that the foot element 54 need not include areashaving different thicknesses or different stiffnesses.

The foot element 54 may include areas having different materialcomposition. Such material variation may lead to areas of the footelement 54 having different stiffnesses. The areas having differentstiffness contribute to a beneficial guided rollover, which is describedin more detail below. Examples of configurations for foot elementshaving areas with different material composition are described below.

FIGS. 28-31 and 34-37 illustrate alternative embodiments for the footelement. The foot elements 88, 90, 92 of FIGS. 28-30 each include twoblades 94, 96, 98, 100, 102, 104 arranged side-by-side lengthwise. Theblades 94, 96, 98, 100, 102, 104 may comprise portions of a unitary footelement including a lengthwise split 106, the split 106 having a gap 108in the arch portion 110 of the element 88, 90, 92. Alternatively, theblades 94, 96, 98, 100, 102, 104 may comprise separate portions that arejoined to one another at the arch portion 110.

The blades 94, 96, 98, 100, 102, 104 may be constructed of the samematerial, or they may be constructed of different materials. Each blade94, 96, 98, 100, 102, 104 may have the same thickness, or one blade 94,96, 98, 100, 102, 104 may be thicker than the other. To guide the foot'scenter of mass medially, the medial blade 94, 98, 102 may have a lesserstiffness than the lateral blade 96, 100, 104. The medial blade 94, 98,102 thus bends more easily than the lateral blade 96, 100, 104, guidingthe rollover toward the medial side. Conversely, to guide the foot'scenter of mass laterally, the medial blade 94, 98, 102 may have agreater stiffness than the lateral blade 96, 100, 104.

In the embodiment of FIG. 28, the blades 94, 96 have approximately equalwidths, and the split 106 runs substantially straight in ananterior/posterior direction. In the embodiment of FIG. 30, the medialblade 102 has a lesser width than the lateral blade 104, and the splitruns 106 substantially straight in an anterior/posterior direction. Inthe embodiment of FIG. 29, the medial blade 98 has a lesser width thanthe lateral blade 100, and the split 106 includes a change in direction.The split 106 runs substantially straight in an anterior/posteriordirection from the posterior edge 112 of the element 90 to the archportion 110. After a short gap 108, the split 106 continuessubstantially straight in an anterior/posterior direction until itreaches approximately a border between the arch portion 110 and the toeportion 114. The split 106 then turns medially and continues to the baseof the U-shaped cutout 116 in the anterior edge 118 of the toe portion58.

FIG. 31 illustrates another alternative embodiment for the foot element.The foot element 93 of FIG. 31 includes two blades 95, 97 arrangedside-by-side lengthwise. The blades 95, 97 may comprise portions of aunitary foot element including a lengthwise split 99 that extends froman anterior edge 101 to a posterior edge 103 thereof. Alternatively, theblades 95, 97 may comprise separate portions.

The blades 95, 97 may be constructed of the same material, or they maybe constructed of different materials. Each blade 95, 97 may have thesame thickness, or one blade 95, 97 may be thicker than the other. Toguide the foot's center of mass medially, the medial blade 95 may have alesser stiffness than the lateral blade 97. The medial blade 95 thusbends more easily than the lateral blade 97, guiding the rollover towardthe medial side. Conversely, to guide the foot's center of masslaterally, the medial blade 95 may have a greater stiffness than thelateral blade 97.

The foot elements 88, 90, 92, 93 described above all include split heeland toe portions. These split portions provide the same advantageousground compliance described above with respect to the split heel portion60.

The embodiment of FIG. 35 comprises a unitary foot element 120. Thecurvature of the blade is angled medially. This angled curvature guidesthe foot's center of mass medially during rollover. In an alternateconfiguration, the curvature of the blade may be angled laterally. Thisangled curvature guides the foot's center of mass laterally duringrollover.

The embodiment of FIG. 36 similarly comprises a unitary foot element122. Side cuts 124 in the medial edge 126 and lateral edge 128 of thetoe portion 130 control the foot element bending angle. In theillustrated embodiment, the side cuts 124 are substantially U-shaped intop plan aspect. Those of skill in the art will appreciate, however,that the side cuts 124 could embody substantially any shape. Forexample, the side cuts 124 could be V-shaped.

The embodiment of FIG. 37 comprises a unitary foot element 132. Atapproximately a border between the toe portion 134 and arch portion 136,a lower surface 138 of the element includes a channel 140. The channel140 runs approximately perpendicular to a longitudinal axis of theelement 132. The channel 140 may, however, run in a direction that isnot perpendicular to the longitudinal axis of the element 132. Forexample, a medial end of the channel 140 may lie posterior to a lateralend of the channel 140, and vice versa.

A depth of the channel 140 increases in the medial direction. In theregion of the channel 140, the medial side of the element 132 is thusmore flexible than the lateral side. This configuration guides thefoot's center of mass toward the medial side during rollover. In analternate configuration, a depth of the channel 140 may increases in thelateral direction. In the region of the channel 140, the lateral side ofthe element 132 is thus more flexible than the medial side. Thisconfiguration guides the foot's center of mass toward the lateral sideduring rollover.

FIGS. 18-20 illustrate the upper element 56 in detail. With reference toFIG. 18, the upper element 56 includes a front portion 142 and a rearportion 144. Although the rear portion 144 of the upper 56 element isillustrated as being substantially planar, those of skill in the artwill appreciate that the rear portion 144 could curve upwardly to form agenerally vertical or angled upper attachment section.

With reference to FIG. 20, the rear portion 144 includes a substantiallysemi-circular posterior edge 146, a substantially straight medial edge148, and a substantially straight lateral edge 150. Those of skill inthe art will appreciate that any of these edges 146, 148, 150 maycomprise different shapes. The front portion 142 includes asubstantially straight lateral edge 152 that extends forward to asubstantially straight anterior edge 154. The anterior edge 154 isslightly angled so that a lateral portion thereof extends forward of amedial portion thereof. An intersection of the lateral edge 152 and theanterior edge 154 defines a rounded corner 156. A medial edge 158 of thefront portion 142 tapers laterally toward the anterior edge 154,intersecting the anterior edge 154 in another rounded corner 160. Thisasymmetrical shape of the upper element 56 provides the foot 50 withadvantageous rollover properties, as described in detail below.

The anterior edge 154 is preferably perpendicular to an axis defined bythe forward walking motion of the wearer. To achieve this configuration,the anterior edge 154 preferably intersects a longitudinal axis of theupper element 56 at an angle between about 3 and 20 degrees, morepreferably about 7 degrees. For most prosthetic foot devices, to mimic anatural human foot, the prosthetic foot is attached such that itslongitudinal axis, defined posterior to anterior, is offset by about 3to 20 degrees, more preferably by about 7 degrees, toward the lateralside, from an axis defined by the forward walking motion of the wearer.Thus, when the present foot 50 is offset in this manner, the angledanterior edge 154 of the upper element 56 is substantially perpendicularto the axis defined by the forward walking motion of the wearer. Thisconfiguration allows for a more evenly distributed bending of the upperelement 56 across the anterior edge 154.

With reference to FIG. 19, the rear portion 144 of the upper element 56is substantially flat, while the front portion 142 curves upwardly. Thiscurvature, in combination with the unique shape of the anterior portionof the ankle member 52, provides the foot 50 with advantageous rolloverproperties, as described in detail below.

With reference to FIG. 20, the rear portion 144 includes first andsecond holes 162. The holes 162 are arranged along a line thatintersects the longitudinal axis of the element 56 substantiallyperpendicularly. The holes 162 are substantially equidistant from thelongitudinal axis. The holes 162 allow fastening members to protrudeupwardly through the upper element 56, as described below.

FIGS. 8-11 illustrate the resilient ankle member 52 in detail. Withreference to FIG. 9, the ankle member 52 is substantially wedge shapedin side elevational aspect. An upper surface 164 of the ankle member 52is substantially flat, but curves upwardly slightly toward an anterioredge 166 thereof. Because the ankle member 52 upper surface 164 issubstantially flat, the upper element 54 is also preferablysubstantially flat at least along a majority of the ankle member 52. Theupper element 54 desirably extends upwardly along this flat portion atan angle of between about 10 and 30 degrees from horizontal, morepreferably about 20 degrees from horizontal, when the foot 50 is atrest.

With reference to FIGS. 8 and 10, a rear portion 168 of the uppersurface 164 includes first and second indentations 170. The indentations170 are arranged along a line that is substantially perpendicular to alongitudinal axis of the ankle member 52. In the assembled foot 50, theindentations 170 receive heads of fastening members, as shown in FIG. 4.

In side elevational aspect (FIG. 9), a rear surface 172 of the anklemember 52 includes a concave curvature of substantially constant radius.Those of skill in the art will appreciate that the curvature need nothave a substantially constant radius. The curved rear surface 172,combined with other features of the ankle member 52, createsadvantageous results at heel strike, as described in detail below.

A lower surface 174 of the ankle member 52 includes a concave curvaturein a rear portion 176 and an intermediate portion 178 thereof, and aconvex curvature in a front portion 180 thereof. With reference to FIG.2, a narrow gap 182 separates the anterior portion 180 of the anklemember 52 from the foot element 54 when the foot 50 is at rest. The gap182 may have virtually any size, and may actually be nonexistent. Thatis, the anterior portion 180 of the ankle member 52 may contact the footelement 54 at 182. Preferably, however, the gap is between 1 mm and 15mm.

Forward of the gap 182, the upward curvature of the ankle memberanterior portion 180 creates a progressively wider wedge-shaped gap 184between the anterior portion 180 and the upper surface 186 of the footelement 54. The gap 184 creates advantageous rollover properties, asdescribed in detail below.

With reference to FIGS. 8 and 9, side surfaces of the ankle member 52include substantially wedge-shaped shallow depressions 188 in rearportions thereof. Each depression 188 includes a border 189 that definesa closed shape and separates the areas of differing elevation on theside surfaces.

Within the depressions 188, the side surfaces include a plurality ofslots 190. Each slot 190 extends into the ankle member 52 in a directionsubstantially perpendicular to a longitudinal axis of the ankle member52. However, the slots 190 preferably do not extend entirely through theankle member 52. Instead, a longitudinally extending wall (not shown)divides the slots 190 on the medial side from those on the lateral side.This wall may be formed integrally with the ankle member 52. Those ofskill in the art will appreciate that the slots 190 could extendentirely through the ankle member 52. In the illustrated embodiment, theankle member 52 includes four slots 190. However, those of skill in theart will appreciate that fewer or more slots 190 could be provided.

The slots 190 are substantially oval or kidney-shaped in sideelevational aspect, transitioning from taller to shorter in an anteriordirection. Preferably, one or more of the slots 190 has a kidney shape.For example, the two slots 190 located most posteriorly include curvedside edges 192 (FIG. 9), with all of these side edges 192 being concavetoward the posterior surface 172 of the ankle member 52. This shapeallows more desired buckling of the ankle member 52 toward its posteriorportion under load. The posterior portion of the ankle member 52 thusprovides additional compression and/or shock absorption, and progressivedampening, as described below. Those of skill in the art will appreciatethat the ovals and/or kidneys may stand substantially straight, or theymay be tilted. Those of skill in the art will further appreciate thatthe curved side edges 192 may face toward the anterior edge 166 of theankle member 52.

The slots 190 are adapted to receive stiffening members, such as thoseshown in FIGS. 12-17. FIGS. 12-14 illustrate stiffening members 194having a curved configuration that is adapted to fit into the curvedslots 190 (two aftmost slots). FIGS. 15-17 illustrate stiffening members196 having a straight configuration that is adapted to fit into thestraight slots 190 (two foremost slots). Note that the stiffeningmembers 194, 196 are not drawn to scale.

The stiffening members 194, 196 are preferably constructed of aresilient and compressible material. A preferred material ispolyurethane foam. The density of the stiffening members 194, 196 may beselected to fine tune the stiffness of the foot 50 to a particular user.In one embodiment, densities of the stiffening members 194, 196 are from0.4 g/cm³ to 0.6 g/cm³.

The stiffening members 194, 196 preferably provide dampening to theankle member 52. The stiffening members 194, 196 also alter the rollovercharacteristics of the foot 50. For a given application, all, some ornone of the slots 190 may contain stiffening members 194, 196. If atleast some of the slots 190 contain stiffening members 194, 196, one ormore of the stiffening members 194, 196 may have different materialproperties, such as density or compressibility, than one or more of theother stiffening members 194, 196. For example, all the stiffeners 194,196 on either the lateral or medial side may have a first set ofmaterial properties, while the stiffeners 194, 196 on the opposite sidehave a second set of material properties. More preferably, stiffeners194, 196 on the medial side may be more compressible than those on thelateral side. This configuration may provide the foot 50 with desirablerollover characteristics, as described in detail below. Of course,stiffeners 194, 196 on opposite sides of the ankle member 52 may haveidentical material properties.

With reference to FIG. 9, between each of the slots 190, and outside theoutermost slots 190, ribs 198 extend generally vertically between theupper and lower surfaces 164, 174 of the ankle member 52. The ribs 198toward the fore 166 of the foot 50 are substantially straight, while theribs 198 toward the aft 172 of the foot 50 are curved. The curved ribs198 are advantageously soft in compression, as they buckle more readilyunder compressive loads as compared to straight ribs. The ankle member52 thus provides advantageous cushioning to the wearer. The curved ribs198 are, however, relatively rigid in tension, providing the foot 50with durability. Those of skill in the art will appreciate that straightribs could be substituted for the curved ribs 198, and the ankle member52 would still provide the advantageous cushioning and durabilitydescribed above.

With reference to FIGS. 8 and 9, a forward portion 180 of the anklemember 52 includes a split 200. The split 200 extends entirely acrossthe ankle member 52, and diagonally upward and backward from the anklemember lower surface 174. Referring to FIG. 9, the split 200 has a largeenough thickness such that surfaces 202, 204 of the ankle member 52 toeither side of the split 200 do not abut one another when the anklemember 52 is in a resting state.

A posterior edge 206 of the split 200 adjoins a substantiallycylindrical cavity 208 in the ankle member forward portion 180. Thecavity 208 extends entirely across the ankle member 52, and providesstress relief to the split 200 The cavity 208 is spaced from the anklemember upper surface 164, from the ankle member lower surface 174, andis positioned forward of the depressions 188 on the ankle member sidesurfaces. The portion 210 of ankle member 52 material between the cavity208 and the side surface depressions 188 acts as a hinge duringrollover, as described below.

Those of skill in the art will appreciate that the illustrated locationand orientation of the split 200 and the cavity 208 is just one possibleconfiguration. For example, the split 200 could be located moreposteriorly, perhaps overlapping a middle portion of the ankle member52. As the position of these features relative to the remainder of theankle member 52 changes, the rotational response of the foot 50 changes.That is, the location and orientation of the split 200 and the cavity208 affects the softness or stiffness of the foot 50 as it rotates inthe sagittal plane during rollover. This concept is explained more fullybelow.

FIGS. 1-3 illustrate the foot 50 in the assembled configuration, whileFIG. 4 illustrates the major components of the foot 50 in an explodedconfiguration. The ankle member lower surface 174 abuts the foot elementupper surface 186, while the ankle member upper surface 164 abuts theupper element lower surface 212. The ankle member 52 is thus sandwichedbetween the foot element 54 and the upper element 56.

Glue or another bonding agent may secure the upper element 56 and thefoot element 54 to the ankle member 52. Alternatively, the ankle member52 may be directly cast onto the upper element 56 and the foot element54. In the direct casting process, the material that forms the anklemember 52 is injected into a mold such that the ankle member materialdirectly contacts the foot element upper surface 186 and the upperelement lower surface 212. As the ankle member material hardens, itadheres to these surfaces 186, 212. The direct casting method canproduce a stronger bond between mating surfaces than glues or otherbonding agents.

The bond between abutting surfaces can be strengthened if the solidsurfaces are roughened prior to performing the direct casting. Forexample, the foot element upper surface 186 and the upper element lowersurface 212 may be roughened before the ankle member 52 is injected intothe mold. One method of roughening these surfaces involves applying arough weave fabric layer to each surface before the surface is cured.After the surface is cured, the cloth is removed, leaving behind aroughened surface.

A male pyramid adapter 214 resides atop the rear portion 144 of theupper element 56. The adapter 214 is positioned directly above thefillet 78 in the foot element 54. The adapter 214 is illustrated indetail in FIGS. 21-26. The adapter 214 is preferably constructed ofmetal. In one embodiment, the adapter 214 is constructed of titaniumand/or aluminum.

With reference to FIG. 21, the adapter 214 comprises a base portion 216and a mating portion 218. The base portion 216 includes a sloped lowersurface 220 (FIG. 22) that sits flush against the sloped upper surface222 of the upper element 56, as shown in FIG. 2. The remainder of thebase portion 216 is shaped so as to present the mating portion 218 in anorientation in which a longitudinal axis 224 of the mating portion 218is substantially vertical, as shown in FIG. 22.

The lower surface 220 of the base portion 216 includes first and secondreceiving holes 226 (FIGS. 23 and 24) that align with the first andsecond holes 162 in the upper element 56 and with the indentations 170in the upper surface 164 of the ankle member 52. As shown in phantomlines in FIG. 2, shafts 228 of the fastening members 230 (FIG. 4)protrude through the first and second holes 162 in the upper element 56.The protruding shafts 228 engage the receiving holes 226 in the pyramidadapter 214, thus securing the pyramid adapter 214 to the upper element56. The fastening members 230 may include external threads, and thereceiving holes 226 may include internal threads.

The upper element 56 is secured to the upper surface 164 of the anklemember 52 such that the head portion 232 (FIG. 4) of each fasteningmember 230 seats within one of the indentations 170 in the upper surface164, as shown in phantom lines in FIG. 2.

With reference to FIGS. 1 and 4, the perimeter of the upper element 56traces substantially the same path as the perimeter of the ankle memberupper surface 164. The upper element 56 is positioned upon the anklemember 52 such that there is substantially no overlap between these twoperimeters. The ankle member 52 is positioned upon the foot element 54such that a fore-to-aft center of the ankle member 52 is positionedrearward of a fore-to-aft center of the foot element 54. With referenceto FIG. 3, a side-to-side center of the ankle member 52 is substantiallyaligned with a side-to-side center of the foot element 54, except in ananterior portion of the ankle member 52, as described below.

FIGS. 38-40 illustrate the foot 50 as it rolls over from heel strike totoe off. Several features of the foot 50 contribute to the advantageousrollover that the foot 50 achieves. For example, at heel strike,illustrated in FIG. 38, the split heel portion 60 stabilizes the foot50, as described in detail above. Further, the resilient sole 234 at theheel 60 compresses at heel strike. The deformation helps to distributeforces over a wider area, which further enhances stability. Thiscompression continues through the wearer's gait, enhancing stability allthe way through.

At heel strike, the curvature and tapered thickness of the foot elementheel portion 60 provide comfort and stability enhancement, as describedin detail above. With reference to FIG. 38, the heel portion 60 of thefoot element 54 bends upward at heel strike. The deforming foot element54 compresses the posterior portion of the ankle member 52. The concavecurvature of the ankle member posterior surface 172, coupled with thecurved shape of the aftmost ribs 198, makes the posterior portion softerin compression. Moreover, the relatively greater thickness of the anklemember 52 in the posterior section provides the foot 50 with morecompression during heel-strike, while also allowing for additionalrotational ability. The ankle member 52 thus provides increasedcushioning at heel strike.

The deformation of the posterior portion of the ankle member 52 at heelstrike is often so pronounced that the aftmost rib 198 buckles andcontacts the next aftmost rib 198, as shown in FIG. 38. The buckling rib198 collapses the aftmost slot 190. If the load upon the foot 50 isgreat enough, additional ribs 198 may buckle and additional slots 190may collapse. The collapsing slots 190 create progressive dampeningwithin the ankle member 52. When the aftmost slot 190 collapses, thestiffness in the ankle member 52 increases due to the increased densityof the ankle member 52. When the next aftmost slot 190 collapses, thestiffness in the ankle member 52 increases even further. Thisprogressive dampening advantageously tailors the responsecharacteristics of the ankle member 52 to the wearer.

With continued reference to FIG. 38, the lack of attachment between theanterior portion 142 of the upper element 56 and the foot element 54eliminates pull in this area during heel strike. The anterior portion142 of the upper element 56 is not constrained from moving away from thefoot element 54. The compression of the posterior portion of the anklemember 52 at heel strike thus generates no tension in the anteriorportion 180 of the ankle member 52, which in turn allows the posteriorportion to compress further. This feature further enhances thecushioning capability of the foot 50. The shape, orientation andlocation of the gap 200 between the facing surfaces 202, 204 of theankle member anterior portion 180 affects the heel stiffness of the foot50. Likewise, the shape, orientation and location of the gap 184 betweenthe ankle member anterior portion 180 and the foot element 54 affectsthe heel stiffness of the foot 50.

At mid stance, illustrated in FIG. 39, several features of the foot 50begin to guide the foot's center of mass inward, toward the medial sideof the foot 50. For example, if the foot 50 includes the functional sole234 described above, the relatively soft material 246 at the ball of thefoot element 54 tends to deform and compress more than the relativelymore firm material 236 surrounding the soft material 246. The mediallocation of the softer material 246 guides the foot's center of massinward.

The asymmetrical upper element 56 further enhances the medially-guidedrollover. With reference to FIGS. 3 and 20, the medial edge 158 of theupper element 56 tapers toward its lateral side from approximately thelengthwise midpoint of the element 56 toward the anterior edge 154thereof. With reference to FIGS. 4 and 10, the upper surface 164 of theankle member 52 shares this perimeter shape. Thus, the ankle member 52provides greater support for the wearer's weight on the lateral side. Asthe wearer's gait progresses forward, this uneven weight support guidesthe foot's center of mass medially, as the foot element is allowed toflex more toward its medial side due to the lack of an overlying anklemember and upper element. The curved taper of the upper element 56 andthe ankle member 52 gradually guides the foot's center of mass fartherand farther medially as the wearer's gait progresses toward toe off.

The addition of stiffening members 194, 196 to the ankle member 52 mayfurther enhance the guided rollover. For example, a stiffener orstiffeners 194, 196 that is/are relatively firm may be positioned withinthe slot(s) 190 on the lateral side of the ankle member 52, while astiffener or stiffeners 194, 196 that is/are relatively soft may bepositioned within the slot(s) 190 on the medial side. Alternatively, astiffener or stiffeners 194, 196 may be positioned within the slot(s)190 on the lateral side of the ankle member 52, while no stiffeners arepositioned within the slot(s) 190 on the medial side. In either case,the lateral side of the ankle member 52 is less compressible than themedial side. As the foot 50 rolls over, the greater compressibility ofthe medial side further guides the foot's center of mass inward.

FIG. 41 illustrates the advantageous guided rollover that the presentfoot 50 achieves. FIG. 41 is a scan of the pressure applied by the foot50 to a walking surface as the foot 50 rolls over from heel strike totoe off. The image on the right maps the pressure applied by the foot50, while the image on the left maps the pressure applied by thewearer's natural left foot. The dots in each image follow the path ofthe center of pressure as it travels through rollover. To mimic the pathfollowed by a natural human foot, this center of pressure preferablystarts at the center of the heel and travels in a substantially straightline until it reaches approximately the ball of the foot. It thenpreferably curves medially and continues toward the wearer's first andsecond toes. Preferably, the distance between each of the dots issubstantially uniform, indicating a smooth rollover with no abruptchanges in speed.

The scan on the right, which follows the path of the center of pressureof the present foot 50, indicates that the present foot 50 provides anadvantageous rollover. The dots are substantially uniformly spaced. Thedots start at the center of the heel and travel in a substantiallystraight line until they reach approximately the ball of the foot. Theythen curve medially and continue toward the wearer's first and secondtoes.

FIGS. 28-37 illustrate several alternative embodiments that achieve theguided rollover described above. For example, the embodiments of FIGS.28-31 and 35-37 include uniquely designed foot elements 88, 90, 92, 120,122, 132. Each of these embodiments is described in detail above, andthe descriptions will not be repeated here.

FIG. 32 illustrates, schematically, a conceptual design for an anklemember 248 that achieves the guided rollover described above. The anklemember 248 comprises a medial portion 250 and a lateral portion 252. Themedial and lateral portions 250, 252 have different stiffnesses. Forexample, the medial and lateral portions 250, 252 could be constructedof different densities of the same material, or they could beconstructed of entirely different materials. In one embodiment, themedial portion 250 has a softer stiffness than the lateral portion 252.With a softer stiffness on the medial side, the medial portion 250compresses more than the lateral portion 252 as the ankle member 248rolls over, thus guiding the foot's center of mass inward. To guide thefoot's center of mass outward (toward the lateral side), the medialportion 250 may have a greater stiffness than the lateral portion 252.

Another alternative ankle member (not shown) includes anterior andposterior portions. The anterior and posterior portions have differentstiffnesses. In one embodiment, the anterior portion has a softerstiffness than the posterior portion. In another embodiment, theanterior portion has a greater stiffness than the posterior portion.

Another alternative ankle member (not shown) comprises a unitary memberwith areas of different stiffness or density. For example, the anklemember may include various layers, with some layers having differentstiffness than other layers. Alternatively, the ankle member couldcomprise a matrix of a first stiffness with pockets or plugs of a secondstiffness.

FIG. 33 illustrates, schematically, another conceptual design for anankle member 254 that achieves the guided rollover described above. Theankle member 254 is shaped substantially as a rectangular parallelepipedhaving a diagonally truncated anterior surface 256. Thus a lateralanterior edge 258 of the ankle member 254 extends farther forward than amedial anterior edge 260. As the ankle member 254 rolls over from midstance to toe off, the lateral side 262 of the ankle member 254 supportsmore and more of the wearer's weight, thus guiding the foot's center ofmass inward. To guide the foot's center of mass outward (toward thelateral side), the configuration of the ankle member 254 may be alteredsuch that the medial anterior edge 260 extends farther forward thanlateral anterior edge 258.

These embodiments may be constructed of a single material, or medial andlateral sides of the ankle member 254 may be constructed of differentmaterials. For example, a medial side 264 of the ankle member 254 may beconstructed of a softer material than the lateral side 262, or viceversa.

FIG. 34 illustrates, schematically, a conceptual design for a footelement 266 that achieves the guided rollover described above. The footelement 266 includes a strip 267 where the foot element 266 has anincreased thickness. In the illustrated embodiment, the strip 267 runsfrom a heel portion 269 of the foot element 266 substantially straightforward to an arch portion 271 thereof. This portion of the strip 267runs substantially parallel to a longitudinal axis of the foot element266, and is positioned laterally of the longitudinal axis. The strip 267then turns slightly toward the lateral side 273 of the foot element 266and continues diagonally forward into a toe portion 275 thereof. Thestrip 267 then turns back toward the medial side 277 of the foot element266 and continues diagonally forward before terminating short of ananterior edge 279 thereof.

The location and shape of the strip 267 contribute to guiding the foot'scenter of mass inward as the foot 50 rolls over. The increased effectivethickness of the foot element 266 increases the stiffness thereof in theregion of the strip 267. Thus, in the heel and arch portions 269, 271,the stiffness of the foot element 266 is greater on the lateral side273. As the strip 267 turns toward the lateral side 273, the width ofthe foot element 266 increases. The positioning of the strip 267 fartherand farther toward the lateral side 273 of a progressively wider footelement 266 increases the tendency of the foot's center of mass to beguided toward the medial side 277.

The strip 267 may be formed as a separate component that is secured tothe upper surface 281 of the foot element 266. Alternatively, the footelement 266 and the strip 267 may be formed as a unitary piece. If thestrip 267 is formed as a separate component, it may be constructed of adifferent material than the foot element 266, or it may be constructedof the same material.

As FIG. 39 illustrates, the curvature of the arch portion 62 of the footelement 54 flattens as the wearer's gait reaches mid stance. Thedeformation of the foot element 54 provides further cushioning to thewearer. Further, as the wearer's gait passes through mid stance theresilient foot element 54 begins to return to its natural shape, thusproviding energy return to the wearer. As the foot passes throughmid-stance, the gap 184 beneath the ankle member 52 closes, such thatthe user now takes advantage of substantially the entire compressiveability of the ankle member 52.

As the wearer's gait transitions from mid stance to toe off (FIGS. 39and 40), the toe portion 58 of the foot element 54 flexes, thusdecreasing a radius of curvature of the toe portion 58. The more thegait progresses toward toe off, the more the foot element 54 flexes. Asthe foot element 54 flexes, its upper surface 186 moves closer to thelower surface 268 of the anterior portion 180 of the ankle member 52. Acontact area 270 (FIG. 39) between these two surfaces 186, 268 graduallyincreases as an anterior edge 272 of the contact area 270 graduallymoves forward. At toe off (FIG. 40), the entire lower surface 268 of theanterior portion 180 of the ankle member 52 contacts the foot elementupper surface 186. This progressively increasing support surface area270 provides increased stability from mid stance to toe off.

The anterior edge 272 of the contact area 270 acts as a fulcrum, and thefoot element 54 pivots about this fulcrum. Because the anterior edge 272travels forward as the wearer's gait approaches toe off, the lever armof the foot element toe portion 58 gradually decreases in length throughthis portion of the wearer's gait. The decreasing lever arm lengthincreases the effective stiffness of the foot element toe portion 58.Thus, the toe portion 58 gradually provides increasing energy returnfrom mid stance to toe off, resulting in a smooth rollover.

The outwardly bulging lateral edge 66 in the toe portion 58 contributesto a more natural toe off. As discussed in detail above, the uniqueconfigurations of the upper element 56 and the ankle member 52contribute to guiding the foot's center of mass inward as the foot 50rolls over. The outwardly bulging lateral edge 66 also contributes tothis beneficial effect. Because the lateral edge 66 bulges outwardly, itprovides leverage for urging the center of mass medially as the foot 50rolls toward toe off.

With reference to FIGS. 38-40, the solid material area 210 between thecylindrical cavity 208 and the foremost rib 198 acts as a hinge throughthe wearer's gait. At heel strike (FIG. 38), the material posterior tothe hinge 210 is in compression. The foot element 54 and upper element56 pivot about the hinge 210 to compress the posterior portion of theankle member 52. The material anterior to the hinge 210 is not intension, due to the lack of connection between the anterior portion 142of the upper element 56 and the foot element 54.

As the foot 50 rolls forward to mid stance, the elements 54, 56 pivot inthe opposite direction to achieve the configuration of FIG. 39. And asthe foot 50 rolls forward toward toe off, the elements 54, 56 continueto pivot in the same direction about the hinge 210, closing the gap 184at the anterior of the ankle member 52 and placing the posterior portionof the ankle member 52 in tension. The relatively long upper element 56reduces tearing forces between the upper element 56 and the posteriorportion 168 of the ankle member 52. Thus, this configuration increasesthe durability of the foot 50.

The location of the hinge 210 affects the heel stiffness and therotational response of the foot 50. As the hinge 210 moves moreposteriorly, the heel becomes softer. As the hinge 210 moves moreanteriorly, the heel becomes stiffer.

The foot 50 illustrated in FIGS. 1-4 is adapted to substitute for anatural right human foot. Those of skill in the art will appreciate thata foot configured as a mirror image about a longitudinal axis of theillustrated foot 50 would be adapted to substitute for a natural lefthuman foot. For example, the foot element 54 illustrated in FIGS. 5-7has such a mirror image configuration. The illustrated foot 50 and itsvarious components are not intended to limit the scope of the claimsthat follow to any particular configuration that is adapted for use as aleft or right foot.

FIGS. 42-46 illustrate another embodiment of the present foot prosthesis300. With reference to FIG. 42, the illustrated foot prosthesis 300comprises a resilient ankle member 302 sandwiched between a lowerelement 304, or foot element 304, and an upper element 306 or ankleelement 306. The ankle member 302, lower element 304 and upper element306 are similar to the corresponding elements of the foot 50 illustratedin FIG. 1.

A male pyramid adapter 308 resides atop a rear portion 310 of the upperelement 306. The adapter 308, which is similar to the adapter 214, isillustrated in greater detail in FIGS. 43-46. The adapter 308 includes athrough-bore 312 in a forward portion 314 thereof (FIG. 43). Alongitudinal axis of the through-bore 312 is perpendicular to a planedefined by the rear portion 310 (FIG. 45) of the upper element 306. Thethrough-bore 312 advantageously reduces the weight of the adapter 308,which in turn reduces the weight of the entire foot 300. Those of skillin the art will appreciate that the adapter 308 need not include thethrough-bore 312.

With reference to FIG. 45, a lower end of the through-bore 312 includesa plug 316. In the illustrated embodiment, the plug 316 is substantiallydisk-shaped, such that it covers an entire area of the upper element 306that would otherwise be exposed by the through-bore 312. In theillustrated embodiment, the plug 316 is about half as thick as the rearportion 310 of the upper element 306. However, those of skill in the artwill appreciate that the plug 316 could be thinner or thicker.

The plug 316 preferably comprises a resilient material, such aspolyurethane. The plug 316 serves a variety of functions. For example,the plug 316 aids in securing the adapter 308 to the upper element 306.During one preferred process of constructing the foot 300, described ingreater detail below, the material that forms the plug 316 flows into agap 318 that exists between the forward portion 314 of the adapter 308and the upper surface 320 of the upper element 306. U.S. patentapplication Ser. No. 10/642,125, filed on Aug. 15, 2003, disclosesfurther details of a prosthetic foot having a gap between an attachmentadapter and an upper element. The gap in the '125 application may or maynot receive a resilient material.

With reference to FIGS. 45 and 46, in the illustrated embodiment, thegap 318 is substantially wedge-shaped, becoming wider toward a frontedge 322 of the adapter 308. The shape of the gap 318 results from thecontour of the lower edge 324 of the forward portion 314, whichpreferably curls upward toward the front edge 322. This shape enablesthe upper element 306 to flex more naturally.

As the prosthesis wearer moves about, at least the forward portion 326of the upper element 306 tends to flex. The greatest amount of flexionoccurs at the toe-off phase of gait. The curled shape of the front loweredge 324 of the adapter 308 preferably mimics the curved shape that theupper element 306 achieves as it flexes. Thus, the front lower edge 324avoids the creation of a stress concentration in the upper element 306.For example, if the front lower edge 324 didn't curl upwardly, andinstead resembled a ninety-degree corner at the intersection of thefront surface 322 and the lower surface 328 (FIG. 46), that sharp comerwould create a fulcrum about which the front portion 326 of the upperelement 306 would flex. The fulcrum would inhibit the natural flexingmotion of the upper element 306, causing the material in the vicinity ofthe fulcrum to flex more than it otherwise would, and to flex about arelatively sharp fulcrum. This unnatural motion would create a stressconcentration in the upper element 306 that could cause the upperelement 306 to fail.

In one embodiment of the present foot prosthesis 300 (the empty gapembodiment), the gap 318 contains no solid material. In this embodiment,nothing impedes the natural flexing of the upper element 306. However,in the illustrated embodiment (the filled gap embodiment), the gap 318contains resilient material, such as polyurethane. In this embodiment,as the upper element 306 flexes, the gap 318 shrinks. As the gap 318shrinks, the resilient material in the gap 318 compresses. Thiscompression provides resistance to the flexing of the upper element 306.

In both the empty gap and filled gap embodiments, the gap 318 affectsthe rollover properties of the foot 300. In the empty gap embodiment,rollover is softest. In the filled gap embodiment, rollover is generallystiffer than the empty gap embodiment, with the stiffness increasing asthe compressibility of the gap-filling material decreases.

The adapter 308 may be secured to the upper element 306 in a fashionsimilar to that described above with respect to the adapter 214 and theupper element 56 of FIG. 4. For example, with reference to FIG. 45, oneor more bolts 330 may secure the adapter 308 to the upper element 306.In the filled gap embodiment, the resilient material advantageouslyreduces stresses in the bolts 330 as the upper element 306 flexes. Forthe filled gap embodiment, testing has shown a 20%-30% decrease in thestresses formed in the bolts as compared to the empty gap embodiment.

In one embodiment of a method to construct the filled-gap embodiment, abarrier (not shown), such as an o-ring, is placed around a lower portion332 (FIG. 45) of the adapter 308 after the adapter 308 is secured to theupper element 306. Resilient material in liquid form is then poured intothe through-bore 312. The resilient material seeps through a narrowopening 334 (FIG. 46) between the adapter front portion 314 and theupper surface 320 of the upper element 306. The resilient material fillsthe gap 318. The barrier prevents the resilient material from flowingoutward any further. Once the resilient material has cooled andhardened, the barrier is removed.

As explained above, the adapter 308 need not include the through-bore312. In an embodiment of the foot 300 that does not include thethrough-bore 312, the resilient material may be applied to the gap 318in alternative ways, such as by injecting it directly into the gap 318from the front of the adapter 308.

SCOPE OF THE INVENTION

The above presents a description of the best mode contemplated forcarrying out the present foot prosthesis with resilient multi-axialankle, and of the manner and process of making and using it, in suchfull, clear, concise, and exact terms as to enable any person skilled inthe art to which it pertains to make and use this foot prosthesis. Thisfoot prosthesis is, however, susceptible to modifications and alternateconstructions from that discussed above that are fully equivalent.Consequently, this foot prosthesis is not limited to the particularembodiments disclosed. On the contrary, this foot prosthesis covers allmodifications and alternate constructions coming within the spirit andscope of the foot prosthesis.

1. A prosthetic foot, comprising: a lower element; an upper element; a resilient ankle member positioned between the lower and upper elements, the ankle member completely separating the lower element from the upper element such that the lower element does not contact the upper element; and an attachment adapter operatively connected to an upper surface of the upper element; wherein a gap exists between a lower front edge of the adapter and the upper surface of the upper element.
 2. The prosthetic foot of claim 1, wherein the lower front edge of the adapter curls upwardly toward a front surface of the adapter, such that the gap becomes wider toward the front surface of the adapter.
 3. The prosthetic foot of claim 1, wherein the gap contains a resilient material.
 4. The prosthetic foot of claim 3, wherein the resilient material comprises polyurethane.
 5. The prosthetic foot of claim 1, wherein the adapter includes a through-bore in a front portion thereof.
 6. The prosthetic foot of claim 5, wherein at least a lower portion of the through-bore contains a resilient material.
 7. The prosthetic foot of claim 6, wherein the resilient material comprises polyurethane.
 8. The prosthetic foot of claim 6, wherein the gap also contains a resilient material.
 9. The prosthetic foot of claim 8, wherein the resilient material contained within the gap comprises polyurethane.
 10. The prosthetic foot of claim 1, wherein the adapter comprises a male pyramid adapter.
 11. The prosthetic foot of claim 1, wherein the upper and lower elements are each substantially plate-like.
 12. The prosthetic foot of claim 1, wherein the upper element includes a substantially flat rear portion and a front portion that curves upwardly.
 13. The prosthetic foot of claim 1, wherein the upper and lower elements are each constructed of a flexible and resilient material.
 14. The prosthetic foot of claim 13, wherein the upper and lower elements are each constructed of carbon, polymer, or a composite.
 15. In combination, an elongate, plate-like element adapted for use in a prosthetic foot and an attachment adapter operatively connected to an upper surface of the elongate, plate-like element, wherein a gap exists between a lower front edge of the adapter and the upper surface and the gap contains a resilient material.
 16. The combination of claim 15, wherein the lower front edge of the adapter curls upwardly toward a front surface of the adapter, such that the gap becomes wider toward the front surface of the adapter.
 17. The combination of claim 15, wherein the resilient material comprises polyurethane.
 18. The combination of claim 15, wherein the adapter includes a through-bore in a front portion thereof.
 19. The combination of claim 18, wherein at least a lower portion of the through-bore contains a resilient material.
 20. The combination of claim 19, wherein the resilient material comprises polyurethane.
 21. The combination of claim 19, wherein the gap also contains a resilient material.
 22. The combination of claim 21, wherein the resilient material contained within the gap comprises polyurethane.
 23. The combination of claim 15, wherein the adapter comprises a male pyramid adapter.
 24. The combination of claim 15, further comprising a second elongate, plate-like element and a resilient ankle member positioned between the two elements.
 25. The combination of claim 15, wherein the elongate, plate-like element includes a substantially flat rear portion and a front portion that curves upwardly.
 26. The combination of claim 15, wherein the elongate, plate-like element is constructed of a flexible and resilient material.
 27. The combination of claim 26, wherein the elongate, plate-like element is constructed of carbon, polymer, or a composite.
 28. A method of constructing a prosthetic foot, the method comprising the steps of: operatively connecting an attachment adapter to an upper surface of an upper element, such that a gap remains between a lower front edge of the adapter and the upper surface; and filling at least a portion of the gap with a resilient material.
 29. The method of claim 28, wherein the adapter includes a through-bore in a front portion thereof, and the step of filling at least a portion of the gap with a resilient material comprises placing the resilient material in liquid form into the through-bore, such that the resilient material seeps into the gap.
 30. The method of claim 29, further comprising the step of placing a barrier around at least a portion of a junction between the adapter and the upper surface, in order to deter the liquid resilient material from flowing out of the gap.
 31. The method of claim 30, wherein the barrier comprises an o-ring. 